Roof bow

ABSTRACT

A roof bow for a vehicle, comprising a vertical face, a curved top flange extending in a first direction, and a straight bottom flange extending in the first direction. Preferably, the roof bow is monolithic with a plurality of apertures in the vertical face that provide clearance for ductwork, wiring, etc. Additionally, the roof bow may comprise horizontally and vertically-extending indented embossments, and rolled embossments about the apertures. Side flanges may additionally extend in the first direction and attach to side walls of the vehicle via an angled connector.

This application claims priority from U.S. Application Ser. No.60/441,894 filed Jan. 21, 2003, which is hereby incorporated herein byreference.

BACKGROUND OF THE INVENTION

This invention relates generally to roof supports for recreationalvehicles, trailers, utility trailers, utility vehicles, such as UnitedParcel Service trucks, buses, horse trailers, semi-trailers and othersimilar vehicles, including single axle, double axle and multi-axlevehicles and more particularly to a curved roof bow for use with suchvehicles.

SUMMARY OF THE INVENTION

In one aspect of the present invention, this is accomplished byproviding a curved roof bow comprising: an elongate member having: avertical face, the vertical face having a horizontally straight loweredge and a curved or arched upper edge, a bottom flange extending in afirst direction from the lower edge of the vertical face, and a topflange extending in the first direction from the curved upper edge ofthe vertical face. Preferably, the curved roof bow is monolithic.

The foregoing and other aspects will become apparent from the followingdetailed description of the invention when considered in conjunctionwith the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a perspective view of a roof bow of the present inventionshowing the curved roof bow installed in a recreational vehicle.

FIG. 2 is a perspective view of a first embodiment of a roof bow, inaccordance with a preferred embodiment of the present invention.

FIG. 3 is a front view of the roof bow illustrated in FIG. 2.

FIG. 4 is a rear view of the roof bow illustrated in FIG. 2.

FIG. 5 is a top view of the roof bow illustrated in FIG. 2.

FIG. 6 is a bottom view of the roof bow illustrated in FIG. 2.

FIG. 7 is a side elevational view of the roof bow illustrated in FIG. 2,the other side being a mirror image thereof.

FIG. 8 a is a side elevational view of a second embodiment of a roofbow, wherein the downward flange extends the entire length of the topflange.

FIG. 8 b is a side view of the roof bow illustrated in FIG. 2, wherein aportion of the downward flange is removed.

FIG. 9 is a side schematic view of a roof bow, illustrated without theend caps.

FIG. 10 is a top plan view of a preferred embodiment of a roof bowblank.

FIG. 11 is an enlarged top plan view of an end of the roof bow blankillustrated in FIG. 10.

FIG. 12 is a rear view of a third embodiment of a roof bow, the roof bowhaving two vertical embossments on each side of the central aperture.

FIG. 13 illustrates a front schematic view of a side of a roof bowattached to a side wall of a vehicle by an angled connector andfasteners.

FIG. 14 illustrates a perspective schematic view of two roof bowsattached to a side wall of a vehicle by an angled connector andfasteners.

FIG. 15 illustrates a schematic top plan view of a fourth embodiment ofa roof bow.

FIG. 16 illustrates a schematic top plan view of a fifth embodiment of aroof bow.

DETAILED DESCRIPTION

The figures illustrate a curved roof bow 10 for use with recreationalvehicles, trailers, utility trailers, utility vehicles, such as UnitedParcel Service trucks, buses, horse trailers, semi-trailers and othersimilar vehicles (collectively, “vehicles”), including single axle,double axles and multi-axles vehicles.

A preferred embodiment of a curved roof bow 10 is illustrated in FIGS.2–9. Curved roof bow 10 comprises a horizontally-extending beam having avertical face 20, a vertical face lower edge 22, a vertical face upperedge 24, a bottom flange 40 extending in a first direction, and a topflange 50 extending in the first direction. The vertical face 20preferably includes a plurality of apertures 30 of predetermined shapesand sizes. As is illustrated in FIG. 3, the vertical face lower edge 22,and thus bottom flange 40, are substantially straight. The bottom flange40 and top flange 50 preferably extend substantially the entire width,or longitudinal extent, of the curved roof bow 10. The vertical faceupper edge 24, and thus top flange 50, preferably has a non-planar,non-linear, or other curved or discontinuous shape, such that the topflange does not lie in a single plane. In a preferred embodiment, thevertical face upper edge 24, and thus top flange 50 is arched or curved,as is illustrated in FIGS. 3–4. However, it is also contemplated thatthe vertical face upper edge 24, and thus top flange 50, may have any ofa plurality of other non-planar shapes such as stepped, or a combinationof angled end portions and straight middle portions.

Preferably, the curved roof bow 10 is monolithic, i.e., formed and bentfrom a single sheet of metal. However, it is also contemplated that theroof bow 10 may be formed by securing two or more sections together toform a finished product. Additionally, it is contemplated that othergauges of steel and other materials can be utilized without deviatingfrom the scope of the present invention. For example, the roof bow 10may be comprised of aluminum, other thin gauge metals, or any of aplurality of other materials that can be formed in a die or molded. Thecurved roof bow 10 may optionally be protected from corrosion bygalvanization, painting or other corrosion protection means.

FIGS. 10–11 illustrate a preferred embodiment of the sheet metal blank10′ of a curved roof bow 10. The sheet metal blank 10′ is advantageousas a starting material if the user desires a monolithic roof bow formedby bending. The sheet metal blank 10′ preferably includes at least onehorizontal embossment 26, which gives the blank 10′ sufficient stiffnessduring the manufacturing process. Additionally, a plurality of verticalembossments 28 may be provided in the vertical face 20, along with oneor more additional horizontal embossments 27.

A plurality of apertures 30 may be formed in the vertical face 20 of thecurved roof bow 10. These apertures 30 may be provided as clearanceholes for marker lights, wiring, ducting, or stay lasts or stiffeners(such as a wood 2×4 to space one curved roof bow from an adjacent roofbow, usually on 16″ centers). Preferably, the round apertures 30 a onthe outboard end of the curved roof provide clearence for marker lightswhen the curved roof bow is installed at the rear of the vehicle. Theoval apertures 30 b next inboard from the round apertures may be usedfor the stay lasts. The oval apertures 30 c next to the stay lastsapertures 30 b may be usually used for wiring. The large apertures 30 dare typically used for ducting, and the center aperture 30 e istypically used for wiring and, when installed at the rear of thevehicle, as clearance for a marker light. It should be understood thatthe aforementioned reference to particular apertures 30 a–30 e inconjunction with particular functions is exemplary; the number and shapeof apertures 30 and the function of any particular aperture can beadapted for particular needs of the vehicle 100 without deviating fromthe scope of the present invention.

One or more of the apertures 30 may have rolled edges or otherembossments to provide a smoother perimeter edge rather than a sharpedge. Such a smooth edge is advantageous when wiring or other materialis pulled through the apertures 30. In a preferred embodiment, one ormore of the apertures 30 a–30 e have embossments 32 as shown in FIG. 9.The first section 32 a of the embossment extends away from the verticalface 20 at an angle. Preferably, the first section 32 a extends at anangle forwardly and inwardly, i.e., toward the center of the aperture30. The second section 32 b of the embossment extends vertically fromthe first section 32 a, and thus is parallel to the vertical face 20.The third section 32 c of the embossment rolls rearwardly, thuseliminating sharp edges about the aperture perimeter. This particulartype of rolled embossment provides additional stiffness to the curvedroof bow and presents a smooth edge to prevent damage to any wirespassing through the apertures.

Further embodiments for the rolled embossments providing a smoothaperture edge are contemplated, and may be utilized without deviatingfrom the scope of the present invention. For example, the third sectionmay roll forwardly, or the first section 32 a and/or second section 32 bcould be eliminated entirely, with simply the perimeter of the aperturesimply being at least slightly rolled in either direction. It is alsocontemplated that the embossments about the apertures can be eliminatedentirely.

The bottom flange 40 and the top flange 50 of the curved roof bow 10preferably extend in the same direction. More preferably, both thebottom flange 40 and the top flange 50 extend forwardly (i.e. toward thefront of the vehicle 100) perpendicular to the vertical face 20.However, it is also contemplated that both the bottom flange 40 and thetop flange 50 extend rearwardly, or that the that flanges 40 and 50extend in opposite directions, or both flanges 40 and 50 extend in bothdirections, similar to an I-beam.

To form the curved roof bow 10 from the a sheet metal blank 10′, such asthe sheet metal blank 10′ illustrated in FIG. 10, the lower portion 40′of the sheet metal blank 10′ is bent about 90°, forming a bottomstraight flange 40. The exposed edge of the bottom flange is bent upwardabout 90°, as shown in FIG. 13, forming an upward flange 42. The upperpart 44 of the upward flange 42 of the bottom flange 40 is then bentapproximately 45° inward towards the vertical face 20, as shown in FIG.13. The upper portion 50′ of the sheet metal blank is bent about 90° inthe same direction as the bottom flange. The edge of the upper flange isbent downward about 90°, forming downward flange 54, as shown in FIG. 2.

In a preferred embodiment, one or more indented or pleated embossments52 are formed in the upper flange, as seen in FIGS. 2, 3, and 4. Theindented embossments 52 are formed to shorten the length of take upexcess material in the top flange 50 upon bending the sheet metal blank10′, which prevents the top flange 50 from buckling or wrinkling duringthe bending process. Additionally, the indented embossments 52 helpstiffen the roof bow 10. The size, number, and orientation of indentedembossments 52 can be altered without deviating from the scope of thepresent invention. For example, the top flange 50 may comprise a singleindented embossment (not shown) that extends longitudinally across thetop flange 50.

In a preferred embodiment, the indented embossments 52 illustrated inFIGS. 2, 3, and 4 preferably may have a 3/16″ radius and are be 3/16″deep. Additionally, the curved roof bow is preferably 94″ long when usedfor an 8′ recreational vehicle and has a 368⅝″ radius of curvature. Assuch, the first top flange indented embossment 52 from the left edge ofthe curved roof bow is preferably 5″ from the left edge, and theremaining top flange indented embossments 52 are 12″ from the precedingembossment, resulting in the right-most embossment 52 being 5″ from theright edge of the curved roof bow. It should be understood that theprecise shape, size, and location of the indented embossments 52illustrated is exemplary only. For example, the indented embossments canbe v-shaped, convex, concave, convoluted, or any of a plurality of othershapes. As such, “indented” is meant to include all examples mentionedabove, and any other similar configurations known in the art.Additionally, the size and location of the indented embossments 52 canbe altered without deviating from the scope of the present invention.

As will be appreciated from one of ordinary skill in the art, withcurved roof bows 10 of different sizes and radii of curvature, thenumber and size of indented embossments 52 may vary. For example, withcurved roof bows 10 that have a greater radius of curvature than theexample specified above, the number or size of embossments 52 may beincreased. Similarly, for curved roof bows 10 that have a lesser radiusof curvature, the size or number of embossments 52 may be decreased.Additionally, if all or a portion of the top flange is straight ratherthan curved or arched, the indented embossments 52 may be reduced oreliminated entirely.

As can be seen in FIGS. 8 a–8 b, the sides of the vertical face 20comprise end caps 60. The end caps 60 preferably extend in the samedirection as the top flange 50 and the bottom flange 40. In a preferredembodiment, the end caps 60 are rectangular. However, it is contemplatedthat side flanges 60 may be any of a plurality of shapes withoutdeviating from the scope of the present invention.

The end caps 60 of the curved roof bow 10 preferably have small tabs 62,64 extending from the top and bottom edges of the end caps 60, shown atthe ends of the sheet metal blank 10′ shown in FIG. 10. These small tabs62, 64 are bent approximately 90° to the end caps 60, as shown in FIGS.8 a–8 b. Preferably, these small tabs 62, 64 are not attached to the topand bottom flanges 40 and 50. However, it is contemplated that the smalltabs 62, 64 and/or other portions of the end caps 60 may optionally beattached to the top flange 50 and/or the bottom flange 40. The smalltabs 62, 64 and end caps 60 help prevent compression of the ends of thecurved roof bow under vertical loads, by providing support for the endsof the top flange 50 and bottom flange 40.

To provide enhanced support for the bottom flange 40 and the top flange50, the tabs 62 and 64 on each end of end cap 60 may be located onopposing sides of both the bottom flange 40 and top flange 50,respectively, as seen in FIGS. 8 a–8 b. To provide a smooth bottomsurface of curved roof bow 10, notch 46, as illustrated in FIGS. 9 and11, may be formed into bottom flange 40, such that tab 64, when bentfrom end cap 60, does not extend below bottom flange 40, as illustratedin FIGS. 8 a–8 b.

A portion 54A of downward flange 54 at the ends of the curved roof bowis preferably cut-away, as shown in FIG. 2, to provide for clearanceduring the various manufacturing processes. However, as illustrated inFIG. 8 a, it is also contemplated that downward flange 54 may becontinuous across the entire length of top flange 50. It is alsocontemplated that downward flange 54 may be eliminated entirely.

FIGS. 13 and 14 illustrate the installation of the curved roof bow 10 ina recreational vehicle 100. An angled connector 70 is attached to thetop of the vehicle side walls 72. Two angled connectors 70 arepreferably used for each curved roof bow 10. The curved roof bow 10 isthen connected at each end to an angled connector 70 via screws, bolts,or any of a plurality of fasteners 74 or fastening means known in theart. Preferably, the ends of the curved roof bow 10 rest on the tops ofthe vehicle side walls 72 when attached.

FIGS. 15 and 16 illustrate further contemplated embodiments of a roofbow 310, 410. As can be seen in FIG. 15, the roof bow 310 may comprise avertical face 40, and thus top or upper flange 50 that is stepped, withthe incremental vertical sections of the flange 50 functioning to gathermaterial, in a similar manner as indented embossments 52. Furthermore,as illustrated in FIG. 16, the roof bow 410 may comprise a top flange 50that comprises two angled portions and a horizontal portion. In thisembodiment, indented embossments may be formed at the junctions betweenthe angled and horizontal portions, or excess material may be removed atthe same junctions prior to forming the upper flange 50.

The forgoing disclosure is illustrative of the present invention and isnot to be construed as limiting thereof. Although one or moreembodiments of the invention have been described, persons of ordinaryskill in the art will readily appreciate that numerous modificationscould be made without departing from the scope and spirit of thedisclosed invention. As such, it should be understood that all suchmodifications are intended to be included within the scope of thisinvention. The written description and drawings illustrate the presentinvention and are not to be construed as limited to the specificembodiments disclosed.

1. A roof bow comprising: a longitudinally-extending monolithic memberhaving: a substantially vertical face, the substantially vertical facehaving a horizontally straight lower edge and a non-planar upper edge;and a flange extending from the upper edge; wherein, the upper flange isformed by bending, the upper flange comprising means for preventing theupper flange from wrinkling during the bending.
 2. The roof bow asrecited in claim 1, further comprising a flange extending from the loweredge of the vertical face.
 3. The roof bow as recited in claim 2,wherein the upper edge flange and the lower edge flange extend in thesame direction.
 4. The roof bow as recited in claim 2, wherein the upperedge flange and the lower edge flange extend substantiallyperpendicularly from the vertical face.
 5. The roof bow as recited inclaim 1, wherein the upper edge flange comprises at least oneembossment.
 6. The roof bow as recited in claim 1, wherein the elongatedmember has a plurality of embossments therein.
 7. The roof bow asrecited in claim 1, wherein the vertical face comprises a plurality ofapertures.
 8. The roof bow as recited in claim 7, wherein perimeters ofthe apertures are at least partially rolled.
 9. The roof bow as recitedin claim 1, wherein the means for preventing wrinkling comprises atleast one indented embossment in the top flange, the indented embossmentextending at an angle to the longitudinal extent of the roof bow. 10.The roof bow as recited in claim 1, wherein respective ends of the roofbow each have an end cap extending from the vertical face.
 11. The roofbow as recited in claim 10, wherein each end cap has at feast one tabextending inwardly.
 12. The roof bow as recited in claim 10, furthercomprising a flange extending from the lower edge of the vertical face,wherein each end cap has two pairs of tabs extending inwardly, the upperedge flange fitting between one pair of tabs, the lower edge flangefitting between the other pair of tabs.
 13. A monolithic roof bowcomprising: a longitudinally-extending member having: a vertical face,the vertical face having a horizontally straight lower edge and a curvedupper edge; an upper flange extending from the non-linear upper edge ofthe vertical face; a longitudinally-extending lower flange extendingfrom the lower edge; and, at least one aperture formed in the verticalface.
 14. The monolithic roof bow as recited in claim 13, wherein thetop flange has a plurality of spaced-apart indented embossments therein.15. The monolithic roof bow as recited in claim 13, wherein a perimeterof the at least one aperture comprises a rolled edge.
 16. The monolithicroof bow as recited in claim 13, wherein the bottom flange has a returnflange extending upward from the bottom flange, the return flange beingspaced from the vertical face and longitudinally extending parallel tothe vertical face.
 17. The monolithic roof bow as recited in claim 13,wherein the top flange has a return flange extending downward from thetop flange, the return flange being spaced from the vertical face andlongitudinally extending parallel to the vertical face.
 18. Themonolithic roof bow as recited in claim 13, wherein the top flange andthe bottom flange extend substantially perpendicular to the verticalface.
 19. The monolithic roof bow as recited in claim 13, whereinrespective sides of the vertical face each have an end cap extendingfrom the vertical face.
 20. The monolithic roof bow as recited in claim19, wherein each end cap has at least one tab extending inwardly. 21.The monolithic roof bow as recited in claim 20, wherein each end cap hastwo pairs of tabs extending inwardly, the upper flange fitting betweenone pair of tabs, the lower flange fitting between the other pair oftabs.
 22. A roof bow for a vehicle, comprising: alongitudinally-extending monolithic member having: a vertical face; atop flange extending from the vertical face; a bottom flange extendingfrom the vertical face; and, end caps extending from the vertical face.23. The roof bow as recited in claim 22, wherein each end cap has atleast one tab extending inwardly.
 24. The roof bow as recited in claim22, wherein each end cap has two pairs of tabs extending inwardly, thetop flange fitting between one pair of tabs, the bottom flange fittingbetween the other pair of tabs.